Download PRO COMP SUSPENSION PN# 55506 96
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2360 Boswell Road Chula Vista, CA 91914 Phone 619.216.1444 Fax 619.216.1474 E-Mail [email protected] PRO COMP SUSPENSION Suspension Systems that Work! PN# 55506 96-06 Jeep TJ Sway Bar Quick Disconnect Kit To Be Used in Conjunction With 3”- 5” Lift Kits This document contains very important information that includes warranty information and instructions for resolving problems you may encounter. Please keep it in the vehicle as a permanent record. Revised: 5/14/07 BILL OF MATERIALS: Part # Description 90-1092 ADAPTER MOUNT 2 2,3 4,5 90-6024 37C150HCS5Z 37C250HCS5Z 37CNNE5Z 37NWSAZ 37NWUS8Y HARDWARE PACK: End Links 3/8-16 X 1 1/2 HEX CAP SCREW GR 5 ZINC 3/8-16 X 2 1/2 HEX CAP SCREW GR 5 ZINC 3/8-16 NYLON INSERT L/N GR 5 ZINC 3/8 SAE FLAT WASHER ZINC 3/8 USS FLAT WASHER GR 8 ZINC/YELLOW 1 2 2 4 4 2 3 2 2,3 2,3 2,3 5 4 4,5 4,5 4,5 90-6046 45359 61150 60859H 600001 HARDWARE PACK: Bushings and Sleeves 5/8" BLACK HOURGLASS BUSHING SLEEVE 5/8" X 3/8" X 1.480" SLEEVE 5/8" BLACK HOURGLASS BUSHING 1 4 2 2 4 - - 90-6523 90-2593 72-050200812 73-05000034 73-06200034 90170A212 90-3579 90-2596 70-0251251800 72-025100512 HARDWARE PACK:End Link Clamps QUICK DISSCONNECT PIN 1/2"-20 NYLOCK NUT 1/2" SAE FLAT WASHER PLATED 5/8" SAE FLAT WASHER PLATED LOCKING PIN SWAY BAR CLAMP SWAY BAR CLAMP SPACER 1/4"-20 X 1 1/4" HEX BOLT GR.8 PLATED 1/4"-20 NYLOCK NUT 2 1 1 1 1 1 1 1 1 1 3 3 3 3 3,4 2,4 2 2 2 90-2638 SWAY BAR END LINK 2 3,4,5 5,6 90-6540 90-3726 90-3728 90-4152 HARDWARE PACK: End Link Retaining Brackets SWAY BAR RETAINER SWAY BAR HOLDER Locking Pin Round 1 1 1 1 1 1 1 4 4 4 Optional Equipment Available from your Pro Qty Comp Illus. Distributor! Winch Spacer, 1” (Front) - Pair: 55496 Steering Stabilizer: 219200 Also, check out our outstanding selection of Pro Comp tires to compliment your new installation! Page 5 5 5 5 5 4,5 4 4 4 Introduction: ♦ This installation requires a professional mechanic! ♦ We recommend that you have access to a factory service manual for your vehicle to assist in the disassembly and reassembly of your vehicle. It contains a wealth of detailed information. ♦ Prior to installation, carefully inspect the vehicle’s steering and driveline systems paying close attention to the tie rod ends, ball joints, wheel bearing preload, pitman and idler arm. Additionally, check steering-to-frame and suspension-to-frame attaching points for stress cracks. The overall vehicle must be in excellent working condition. Repair or replace all worn or damaged parts! ♦ Read the instructions carefully and study the illustrations before attempting installation! You may save yourself a lot of extra work. ♦ Check the parts and hardware against the parts list to assure that your kit is complete. Separating parts according to the areas where they will be used and placing the hardware with the brackets before you begin will save installation time. ♦ Check the special equipment list and ensure the availability of these tools. ♦ Secure and properly block vehicle prior to beginning installation. ♦ ALWAYS wear safety glasses when using power tools or working under the vehicle! ♦ Use caution when cutting is required under the vehicle. The factory undercoating is flammable. Take appropriate precautions. Have a fire extinguisher close at hand. ♦ Foot pound torque readings are listed on the Torque Specifications chart at the end of the instructions. These are to be used unless specifically directed otherwise. Apply thread lock retaining compound where specified. ♦ Please note that while every effort is made to ensure that the installation of your Pro Comp lift kit is a positive experience, variations in construction and assembly in the vehicle manufacturing process will virtually ensure that some parts may seem difficult to install. Additionally, the current trend in manufacturing of vehicles results in a frame that is highly flexible and may shift slightly on disassembly prior to installation. The use of pry bars and tapered punches for alignment is considered normal and usually does not indicate a faulty product. However, if you are uncertain about some aspect of the installation process, please feel free to call our tech support department at the number listed on the cover page. We do not recommend that you modify the Pro Comp parts in any way as this will void any warranty expressed or implied by the Pro Comp Suspension company. INSTALLATION INSTRUCTIONS: FRONT SWAY BAR: 1. Position your vehicle on a smooth, flat, hard surface (i.e. concrete or asphalt). Block the rear tires and set the emergency brake. 2. Place the vehicle in neutral. Place your floor jack under the front axle and raise the front of the vehicle. Place jack stands under the frame rails to support the vehicle. 3. Unbolt and remove factory sway bar end links. 4. Install hour glass bushings (600001) and (61150) sleeve in the top and (60859H) sleeve in the bottom of the sway bar end links (90-2638). 5. Remove the OE inner fender bolts shown in ILLUSTRATION 1. Save the hardware for reuse. 6. Install the sway bar inner fender bracket (90-3728) into the inner fender using the previously removed OE bolts into their original holes. See ILLUSTRATION 1. 7. Install sway bar clamp (90-3579) onto sway bar approximately 6” from the end of the bar with the holes facing down. Secure it OE Inner Fender Bolt to the sway bar using the 1/4”-20 X 1 1/4” bolt, spacer (90-2596) and hardware in the top hole (closest to the sway bar). Leave hardware loose at this time. See ILLUSTRATION 2. 8. Install the adapter (90-1092) and sway bar retaining bracket (90-3726) onto the sway bar using the 3/8” X 1 1/2” bolt and hardware as shown in ILLUSTRATION 2. 9. Install sway bar end links (90-2638) into the adapter (90-1092) using the 3/8” X 2 1/2” bolt and hardware. NOTE: The jog in the sway bar will face towards the outside of the vehicle. See ILLUSTRATION 3. 10. Secure the quick disconnect pin (902593) to the factory lower sway bar mount location using the supplied 1/2” washer and 1/2” nylock nut. NOTE: The pin will face toward the inside of the vehicle. See ILLUSTRATION 3. 11. Slide the lower end of the sway bar end link onto the quick disconnect pin and secure Illustration 2 Sway Bar Clamp and Adapter Install Sway Bar Sway Bar Clamp 90-3579 90-3728 Sway Bar Inner Fender Bracket 3/8” x 1 1/2” Bolt 1/4” X 1 1/4” Bolt and Hardware 90-3726 Sway Bar Retainer 90-2596 1/4” Spacer Inner Fender Adapter 90-1092 Illustration 1 Sway Bar Fender Bracket Install Adapter 90-1092 Illustration 3 3/8” x 2 1/2” Bolt Sway Bar and pin Install Lower Locking Pin 90170A212 Sway Bar End Link 90-2638 Sway Bar End Link 90-2638 Finished Lower Mount 1/2” Hardware Sway Bar Clamp 90-3579 Illustration 4 Sway Bar Disconnected Lower Locking Pin 90170A212 Sway Bar End Link Quick Disconnect Pin 90-2593 Lower Axle Mount with the locking pin 90170A212 and 5/8” washer. See ILLUSTRATION 3. 12. Repeat on the remaining side of the vehicle. 13. Temporarily install the front wheels and turn lock to lock to check for interference. When Disconnected: 14. When disconnecting the sway bar links, swing the end links up into the previously installed clamp on the sway bar above. Secure the sway bar end link (90-2638) into the clamp (90-3579) using the previously removed locking pin 90170A212. See ILLUSTRATION 4. 15. Once the sway bar has been raised into the clamp and secured the 1/4” x 1 1/4” bolt and hardware can be tightened down. See ILLUSTRATION 4. 16. Repeat on the remaining side of the vehicle. 17. Secure the sway bar to the sway bar inner fender bracket (90-3728) by inserting the upper locking pin (90-4152) through the sway bar retaining bracket (90-3726) and the inner fender bracket. See ILLUSTRATION 4. 18. Lock the pin (90-4152) in place by securing the clevis over the opposite end of the locking pin. See ILLUSTRATION 5. 19. Reinstall the front wheels and tires. Torque the lug nuts according to factory specifications. 20.Cycle steering lock to lock and inspect steering, suspension and driveline systems for proper operation, tightness and adequate clearance. Recheck brake hose/fitting for leaks. Be sure all hoses are long enough. NOTES: ⇒ After 100 miles recheck for proper torque on all newly installed hardware. ⇒ Recheck all hardware for tightness af- ter off road use. 90-4152 Upper Locking Pin 90-3728 Sway Bar Inner Fender Bracket 90-3726 Sway Bar Retainer Locking Clevis Illustration 5 Sway Bar to fender bracket Bolt Torque and ID Decimal System Bolt Size 5/16 3/8 7/16 1/2 9/16 5/8 3/4 Metric System All Torques in Ft. Lbs. Grade 5 Grade8 Bolt Size Class 9.8 Class 10.9 Class 12.9 15 20 M6 5 9 12 30 45 M8 18 23 27 45 60 M10 32 45 50 65 90 M12 55 75 90 95 130 M14 85 120 145 135 175 M16 130 165 210 185 280 M18 170 240 290 T T D D L 1/2-13x1.75 HHCS D T L L G X Grade 5 Grade 8 (No. of Marks + 2) G = Grade (Bolt Strength) D = Nominal Diameter (Inches) T = Thread Count (Threads per Inch) L = Length (Inches) X = Description (Hex Head Cap Screw) M12-1.25x50 HHCS D T L X P = Property Class (Bolt Strength) D = Nominal Diameter (M illimeters) T = Thread Pitch (Thread Width, mm) L = Length (M illimeters) X = Description (Hex Head Cap Screw) P Notice to Owner operator, Dealer and Installer: Vehicles that have been enhanced for off-road performance often have unique handling characteristics due to the higher center of gravity and larger tires. This vehicle may handle, react and stop differently than many passenger cars or unmodified vehicles, both on and off–road. You must drive your vehicle safely! Extreme care should always be taken to prevent vehicle rollover or loss of control, which can result in serious injury or even death. Always avoid sudden sharp turns or abrupt maneuvers and allow more time and distance for braking! Pro Comp reminds you to fasten your seat belts at all times and reduce speed! We will gladly answer any questions concerning the design, function, maintenance and correct use of our products. Please make sure your Dealer/Installer explains and delivers all warning notices, warranty forms and instruction sheets included with Pro Comp product. Application listings in this catalog have been carefully fit checked for each model and year denoted. However, Pro Comp reserves the right to update as necessary, without notice, and will not be held responsible for misprints, changes or variations made by vehicle manufacturers. Please call when in question regarding new model year, vehicles not listed by specific body or chassis styles or vehicles not originally distributed in the USA. Please note that certain mechanical aspects of any suspension lift product may accelerate ordinary wear of original equipment components. Further, installation of certain Pro Comp products may void the vehicle’s factory warranty as it pertains to certain covered parts; it is the consumer’s responsibility to check with their local dealer for warranty coverage before installation of the lift. Warranty and Return policy: Pro Comp warranties its full line of products to be free from defects in workmanship and materials. Pro Comp’s obligation under this warranty is limited to repair or replacement, at Pro Comp’s option, of the defective product. Any and all costs of removal, installation, freight or incidental or consequential damages are expressly excluded from this warranty. Pro Comp is not responsible for damages and / or warranty of other vehicle parts related or non-related to the installation of Pro Comp product. A consumer who makes the decision to modify his vehicle with aftermarket components of any kind will assume all risk and responsibility for potential damages incurred as a result of their chosen modifications. Warranty coverage does not include consumer opinions regarding ride comfort, fitment and design. Warranty claims can be made directly with Pro Comp or at any factory authorized Pro Comp dealer. IMPORTANT! To validate the warranty on this purchase please be sure to mail in the warranty card. Claims not covered under warranty• Parts subject to normal wear, this includes bushings, bump stops, ball joints, tie rod ends and heim joints • Discontinued products at Pro Comp’s discretion • Bent or dented product • Finish after 90 days • Leaf or coil springs used without proper bump stops • Light bulbs • Products with evident damage caused by abrasion or contact with other items • Damage caused as a result of not following recommendations or requirements called out in the installation manuals • Products used in applications other than listed in Pro Comp’s catalog • Components or accessories used in conjunction with other manufacturer’s systems • Tire & Wheel Warranty as per Pro Competition Tire Company policy • Warranty claims without “Proof of Purchase” • Pro Comp Pro Runner coil over shocks are considered a serviceable shock with a one-year warranty against leakage only. Rebuild service and replacement parts will be available and sold separately by Pro Comp. Contact Pro Comp for specific service charges. • Pro Comp accepts no responsibility for any altered product, improper installation, lack of or improper maintenance, or improper use of our products. E-Mail: [email protected] Website: www.explorerprocomp.com Fax: (619) 216-1474 Ph: (619) 216-1444 PLACE WARRANTY REGISTRATION NUMBER HERE: __________________